Catalytic conversion of hydrocarbons by improved zeolite catalyst

ABSTRACT

A method for catalytically converting hydrocarbon wherein hydrocarbon is contacted at hydrocarbon conversion conditions with a catalyst comprising a metal, hydrogen ion-exchanged aluminosilicate prepared by a process comprising heating an aqueous slurry of a nitrogen compound which hydrolyzes slowly to form ammonia, a metal salt and an ammonium-exchanged crystalline aluminosilicate to allow the metal to precipitate within the lattice structure of the aluminosilicate, and subsequently calcining the aluminosilicate to remove ammonia and form a heat-stable metal, hydrogen ion-exchanged aluminosilicate.

This application is a continuation-in-part of application Ser. No. 40,352, filed May 25, 1970.

This invention relates to an improved method for catalytically converting hydrocarbons. More particularly, this invention is directed to an improved method of hydrocarbon conversion involving acid catalyzed reactions of hydrocarbons using catalysts described hereinafter.

In recent years, the use of ion-exchanged, crystalline aluminosilicates as catalytic materials in the petroleum and chemical industries for reactions of hydrocarbons such as hydrocracking, isomerization, cracking, etc., has become increasingly important. Numerous crystalline aluminosilicates, derived from both natural and synthetic materials, have been utilized to prepare catalytically-active, ion-exchanged crystalline aluminosilicates. Problems regarding thermal stability have, however, been attendant the use of such crystalline aluminosilicates in these high temperature reactions.

Therefore, one object of the present invention is to provide an improved hydrocarbon conversion method involving the use of a catalyst comprising at least one of certain metal, hydrogen ion-exchanged aluminosilicates. Other objects and advantages of the present invention will become apparent hereinafter.

By "hydrocarbon conversion method" is meant, in general, those processes for improving the octane number of gasoline or converting heavy hydrocarbons to light, low boiling hydrocarbons or converting hydrocarbons by hydrogenation or dehydrogenation to, for example, aromatics. Hence, among those processes included in the term "hydrocarbon conversion" are isomerization, reforming, cracking, polymerization, alkylation, dealkylation, hydrogenation, dehydrogenation and hydrocracking and the like.

The present hydrocarbon conversion methods involve using catalysts comprising certain aluminum, zirconium and chromium hydrogen ion-exchanged crystalline aluminosilicates. Outstanding benefits, e.g., enhanced catalytic thermal stability and catalytic activity, are thereby achieved.

Both natural and synthetic crystalline aluminosilicates having pores of diameter in the range from about 6A to about 15A and silica-to-alumina mole ratios of about 2 to about 20 are suitable in preparing the catalysts useful in the method of this invention. Among such naturally-occurring crystalline aluminosilicates are, for example, faujasites and mordenite. The synthetic crystalline aluminosilicates are generally prepared by precipitation from aqueous solutions of aluminum, silicon and alkali metal compounds, particularly salts and oxides. The precipitate is generally aged for one or more days to allow crystallization to occur. A general formula for many of these synthetic cyrstalline aluminosilicates is:

    Q Na.sub.2 O : Al.sub.2 : W SiO.sub.2 : X H.sub.2 O

in which Q is more than 0.2 but less than 1.1, W is from about 2 to about 20 and X is up to about 9. Synthetic crystalline aluminosilicates sold commercially as "Zeolite Y" wherein Q has values of from 0.7 to 1.1 and W has values of from 4 to 5 are a preferred type. Preferred crystalline aluminosilicates have pores of relatively uniform size of about 8A to about 15A in diameter, and a silica-to-alumina mole ratio of about 3.5 to about 6, more advantageously about 4 to about 5. An example of the latter has a molar composition equivalent to 0.9-1.1 Na₂ O . 1A₂ O₃ . 4 SiO₂ and the unit cell thereof is stated to be Na₆₄ . Al₆₄ Si₁₂₈ O₃₈₄ .216H₂ O. These aluminosilicates are three-dimensional, porous lattices having relatively good uniformity as indicated by X-ray diffraction patterns. However, until modified in some manner, such starting alkali metal-containing aluminosilicates are not normally useful in promoting acid-catalyzed reactions. Synthetic crystalline aluminosilicates useful in this invention may also be prepared by treatment of certain clays with aqueous caustic solution, followed normally by heat calcination to remove water. In some cases, these aluminosilicates are recombined with water before use.

A finely divided alkali metal-containing crystalline aluminosilicate, which usually has a particle size of below about 15 microns, preferably below about 10 microns, may be combined with an aqueous solution of an ammonium compound, particularly salts such as ammonium nitrate, for example, to replace a substantial majority, more advantageously more than about 70%, of the initial alkali metal content with ammonium ions. Preferably more than about 90%, most preferably more than about 95%, of the initial alkali metal content is replaced. The replacement of a majority of the initial alkali metal with ammonium ions may be accomplished by carrying out the treatment with aqueous ammonium solution repeatedly to achieve adequate exchange. Alternatively, such an ammonium-exchanged crystalline aluminosilicate may be purchased commercially. Thus, the ammonium exchange itself does not comprise a necessary step in the invention herein.

The aluminum, zirconium and chromium-exchanged crystalline aluminosilicates useful as catalyst components in the present invention are prepared according to the following general scheme. The ammonium-exchanged alumino-silicate is treated with an aqueous solution containing urea or another nitrogen-containing compound which hydrolyzes slowly to form ammonia, and a water-soluble aluminum, zirconium or chromium salt to partially exchange a portion of the ammonium ions and probably a further portion of any remaining alkali metal content with the polyvalent metal ion, apparently in hydrated form. During this treatment, the aqueous slurry is heated, say, above about 75°F., preferably above about 150°F., to effect hydrolysis of the nitrogen compound; however, the temperature is usually below the boiling point of the solution. The hydrolysis results in a controlled increase in the alkalinity of the solution and precipitation within the lattice of the aluminosilicate of aluminum, zirconium or chromium ions, apparently as one or more hydrates of the metals. It is believed that the ammonia formed from the hydrolysis of urea, or other substance forming ammonia slowly on hydrolysis, provides ammonium hydroxide which reacts stoichiometrically with the metal to precipitate the metal in its hydrated form in the lattice of the crystalline aluminosilicate. The metal apparently becomes exchanged into the crystalline aluminosilicate structure. This treatment adds a minor amount, normally about 0.5 to 15, preferably about 1 to 10, percent based on the total weight of the exchanged material (ignited weight basis), of metal in the lattice, and the solid phase can then be recovered by filtration, centrifugation and other known methods of liquid-solids separation. The amount of metals precipitated and apparently exchanged may even be greater than indicated provided the precipitation procedure is slow enough. Preferably, however, up to about 4 weight percent of aluminum, about 8 weight per cent of chromium or about 10 weight percent of zirconium, based on the total exchange and on an ignited weight basis, is normally advantageous for improved thermal stability and catalytic activity. The recovered solid phase may be washed with an aqueous medium and dried, preferably at about 220°F., to remove a large portion of the wash liquid.

The metal, ammonium ion-exchanged aluminosilicate is then calcined, say, at a temperature of at least about 700°F. and preferably above about 900°F., up to about 1700°F., preferably up to about 1400°F., to decompose the ammonium ions present in the lattice. This heating process releases ammonia, leaving hydrogen protons in the lattice. The ammonium decomposition process seems essentially complete after the temperature reaches about 900°F. During this heating step, a substantial portion of water, both in the lattice and apparently from the metals believed to be present in hydrated form, is also removed, but the treatment is not so severe that there is undue loss of crystallinity. The product is a metal, hydrogen ion (proton)-exchanged crystalline aluminosilicate which has been found to be useful as a catalytically active component in a hydrocarbon conversion catalyst having enhanced thermal stability and catalytic activity. After calcination, the metal or metals associated with the aluminosilicate are believed to be present as their oxides.

Therefore, the necessary principle of operation of the procedure outlined above is to provide the nitrogen compound which hydrolyzes slowly to form ammonia and the metal salt in a heated aqueous slurry of the aluminosilicate and allow the metal, apparently as its hydrate, to affiliate by precipitation with the lattice structure of the aluminosilicate and then heat the aluminosilicate to calcination temperatures to remove ammonia and form protons, thus stabilizing the metal, hydrogen ion-exchanged product.

It is believed that the slow addition and precipitation of the metal ions allows the ions to be associated with points of lattice defects prior to precipitation as the hydrate, thus eventually providing increased thermal stability to the product aluminosilicate. Thus, it may be possible to use larger amounts of metals if the precipitation is sufficiently slow. Furthermore, it is significant to use urea or some other similar nitrogen compound such as water-soluble amines and amides such as hexamethylene tetramine and other such amines which hydrolyze slowly to form ammonia, as compared to use of ammonia itself or its salts. Example V indicates the significance of the use of such nitrogen-containing, hydrolyzable compounds rather than ammonia or an ammonium salt during the precipitation step.

The nitrogen containing compounds useful to prepare the metal, hydrogen ion-exchanged aluminosilicates useful in this invention are thus those which hydrolyze to yield ammonia slowly enough that the nitrogen compound might be distributed homogeneously throughout the metal-exchange slurry before significant decomposition to ammonia takes place. Such slow, controlled hydrolysis (decomposition) of the nitrogen containing compound avoids localized high ammonia concentrations and concommitant reduced thermal stability of the final crystalline aluminosilicate. It has been determined that addition rates of the metal to the slurry of the crystalline aluminosilicates measured in terms of moles of metal (aluminum, zirconium or chromium) per gram of aluminosilicate on ignited basis, per minute should advantageously be less than about 1 × 10.sup.⁻⁵, preferably less than about 5 × 10.sup.⁻⁶, to provide hydrocarbon conversion catalysts having the improved thermal stability and catalytic activity contemplated herein.

The metal, hydrogen ion-exchanged aluminosilicates useful in the present invention can be employed directly as a catalyst or can be combined with other suitable catalytic materials or binders. Many of these additional catalytic materials or binders are conventional and well known in the art. Typical among these conventional components are alumina, silica, silica-alumina, clays and mixtures thereof. Typical examples of these clays include halloysite, kaolinite, mortmorillonite, bentonite and mixtures thereof. In addition, these components may also contain minor amounts of other inorganic oxides such as magnesia, zirconia and the like.

The particular chemical composition of the support or binder is not critical. It is, however, necessary that the support or binder employed be thermally stable under the conditions at which the hydrocarbon conversion is carried out. The support or binder may be catalytically inert or possess catalytic activity.

Depending upon the particular hydrocarbon conversion application involved, the catalysts containing presently useful metal, hydrogen ion-exchanged-aluminosilicates may be provided with minor, catalytic amounts of one or more catalytically active metals. Among the metals which are catalytically active for one or more hydrocarbon conversion processes include those of Group IVB, VB, VIB, VIIB and Group VIII of the Periodic Table and mixtures thereof. The catalytically active metals may be dispersed upon the presently useful aluminosilicates in their elemental state or as oxides or compounds, such as sulfides, having catalytic properties. Among the metals and their oxides which have hydrocarbon conversion activity are copper, silver, gold, zinc, cadmium, titanium, tin, lead, vanadium, antimony, bismuth, chromium, molybdenum, tungsten, manganese, rhenium, iron, cobalt, nickel, the platinum group metals and mixtures thereof. The presently useful metal, ion-exchanged aluminosilicates may be used to catalyze various hydrocarbon conversion reactions; for example, isomerization, cracking, hydrocracking, alkylation, reforming, polymerization, disproportionation, hydrogenation and the like. The hydrocarbon conversion method of the present invention involves contacting a hydrocarbon feed with a catalyst comprising at least one of the presently useful metal, hydrogen ion-exchanged aluminosilicates at hydrocarbon conversion conditions. As a result of this contacting, at least a portion of the hydrocarbon feed is chemically converted to different, and often more valuable, products. The conditions at which the contacting takes place are, of course, dependent upon the particular application involved. However, in each application, the conditions used are conventional, well known in the art and, therefore, need not be listed here. By way of example, typical reaction conditions for hydrocarbon cracking and hydrocarbon reforming are as follows.

Reaction conditions depend on the type of catalytic cracking process employed, whether fixed bed, moving bed, or fluidized bed. Furthermore, the cracking conditions depend on the nature of the feedstock, for example, whether highly paraffinic or aromatic, etc., and upon the nitrogen content. In general, the reaction conditions, such as temperature, pressure, and liquid hourly space velocity are correlated to provide the yield and nature of products desired.

The temperature in the catalytic cracking operation often lies in the range from about 700°F. to about 1200°F., preferably from about 800°F. to about 1000°F. Generally, increasing the reaction temperature increases the amount of cracking or the conversion of feed to lower boiling products.

The cracking reaction can be carried out at pressures ranging from subatmospheric to about several atmospheres or more. Preferably, the reaction pressure will range from about 5 psig. to about 100 psig, and more preferably, from about 5 psig. to about 20 psig. The catalytic cracking reaction is generally carried out in the essential absence of added free molecular hydrogen. Increasing the pressure generally reduces the octane quality of the gasoline product and increases the production of coke at a given conversion.

The liquid hourly space velocity in catalytic cracking operations is preferably maintained within the range from about 0.5 to about 20, more preferably from about from about 1 to about 5. The catalyst to oil ratio often is maintained from about 1 to about 20 on a weight basis, preferably from about 2 to about 10. The catalyst to oil ratio depends on the type of process used, e.g., whether a fluidized bed, moving bed or fixed bed. Generally, higher catalyst to oil ratios are used for fluidized bed operations. Increasing the catalyst to oil ratio normally reduces the extent of catalyst deactivation from coke production, and increases the conversion of the feed to lower boiling products.

Typical conditions for hydrocarbon reforming are as follows.

The catalyst employed in such reforming operations normally includes at least one platinum group metal. Other promotors, e.g., rhenium, germanium, tin, gold, lead and the like, may also be present. Temperatures in the range from about 800°F. to about 1000°F. and pressures of about 50 psig. to about 500 psig. are preferably maintained in the reaction zone or zones. Hydrogen is preferably supplied in a molar ratio of about 2 to about 20 moles of hydrogen per mole of hydrocarbon feedstock. Conventionally, the hydrogen concentration is maintained by recycling hydrogen-rich gas to the reaction zone. The weight hourly space velocity is often in the range of about 1 to about 30, and preferably about 2 to about 15. The reforming process may be performed in a series of reaction stages; that is, a plurality of reactors or reaction zones is provided for series contact with the feed and heaters are usually provided between the individual reactors or zones to assure the proper reaction temperature.

The following examples of a non-limiting nature are included to illustrate the present invention.

EXAMPLE I

In this example an ammonium-exchanged aluminosilicate is produced from a sodium aluminosilicate and ammonium nitrate reactants. In brief, ten exchanges were made, using Union Carbide Corporation "SK-40" ¹ and ammonium nitrate, followed by water washings. In more detail, the procedure was as follows:

                                  Approx-                                          Ex-                           imate   Maximum                                  change                                                                               Water,  NH.sub.4 NO.sub.3                                                                       Grams  Heating Temp. during                             No.   Liters  Grams    "SK 40"                                                                               Period  Exchange °F.                      ______________________________________                                         1     1.44    534      1016   1 Hr.   167                                      2     1.0     280      1016   1 Hr.   176                                      3     1.0     280      1016   1 Hr.   173                                      4     1.0     280      1016   1 Hr.   173                                      5     1.0     280      1016   1 Hr.   177                                      6     0.5     140      508    1.4 Hrs.                                                                               178                                      7     0.5     140      508    1 Hr.   185                                      8     0.5     140      508    1 Hr.   185                                      9     0.5     140      508    1 Hr.   183                                      10    0.5     140      508    1 Hr.   179                                      Plus water washings:                                                           1     0.4     None     508    0.5 Hr. 185                                      2     0.4     None     508    0.5 Hr. 178                                      3     0.4     None     508    0.5 Hr. 174                                      ______________________________________                                    

The filter cake was dried at 230°F. and processed to pass a 60 mesh (Tyler) sieve. The analysis was the following: 24.4% loss when heated to 1000°C., representing NH₃ and H₂ 0: 5.21% nitrogen, from ammonium radicals; 1.42% sodium: 10.3% aluminum, and 25.2% silicon. By calculating to a water-free basis, one finds 6.91% nitrogen from NH₄ +, 1.88% Na, 13.6% Al, and 33.4% Si. The X-ray pattern indicated a very good retention of the lattice structure; i.e., esigma value² = 76.4 cms, compared to sigma value of about 80 cms for untreated "SK-40".

    wt.% silica      63.5                                                          wt.% alumina     23.5                                                          wt.% sodium oxide                                                                               13.0                                                          surface area     550 sq.m./gram                                                initial water content                                                          about 60 weight percent                                                        average particle size                                                          about 5 microns                                                                ultimate crystal size                                                          about 1 micron                                                            

EXAMPLE II

The product of this example is a preferred aluminum-hydrogen ion-exchanged crystalline aluminosilicate formed from aluminum added equivalent to about two percent by weight of added aluminum on an ignited basis. The reactants were as follows:

    13.7 g. Al(NO.sub.3).sub.3. 9H.sub.2 O

50 g. Ammonium-exchanged aluminosilicate formed by the technique of Example I

3.4 g. Urea; and, water

The aluminosilicate had the following analysis:

29.2% volatile at 1000°C., including H₂ O and NH₃

4.2% nitrogen from NH₄ + radicals

1.1% sodium

9.76% aluminum

The latter calculates to 13.8% aluminum on an ignited basis.

A Waring Blender was applied to distribute the ammonium-exchanged aluminosilicate in 0.35 liters of water, and then it was transferred to a tall-form Berzelius beaker. With rinse water, the total volume was close to 0.5 liters. The suspension was stirred and heated, while 0.2 liters of solution containing the aluminum nitrate and urea was added during 265 minutes, while the temperature was 184°-186°F. Digestion was continued for a total of 20 hours with an average temperature of about 191°F. Numerous increments of hot water were added to replace evaporation losses. The solid was separated by filtration and three washings with 0.15 liter of water applied. The washed material was dried at about 230°F. and processed to pass a twenty mesh (Tyler) sieve. The dried product upon analysis showed 15.8% aluminum on ignited basis. Thus, there was a gain of 2.0% by weight of aluminum on an ignited basis. Additionally, the rate of addition of aluminum (moles thereof) per gram of aluminosilicate on an ignited basis per minute for this Example is calculated at about 2.8 × 10.sup.⁻⁶ moles Al+++/gram aluminosilicate/minute.

Part of the product was mixed with 4% flake graphite, then tabletted, broken, and sized to separate 10-14 mesh (Tyler) particles. These were heated in a temperature-programmed, air atmosphere, electric muffle for 5 hours at 900°F. The product had a sigma value of 43.7 cms., and a surface area of 825 sq.m. per gram. This product was found to have an outstanding activity to isomerize isobutane when compared to several other catalysts.

By heating part of the aluminum, hydrogen ion-exchanged product for 2 hours at 1350°F., an aluminum, hydrogen ion-exchanged product having a sigma value = 36.7, and a surface area = 740 sq.m/g was prepared.

EXAMPLE III

The product of this example is another closely related to that of Example II, but prepared with a shorter processing time and the use of NH₄ OH after urea addition to raise the pH. The reactants were as follows:

    58.2 g. Al(NO.sub.3).sub.3. 9H.sub.2 O

199 g. Ammonium-exchanged aluminosilicate formed by the technique of Example I

14.5 g. Urea; water; and 50 ml. 3M NH₄ OH

The aluminosilicate had the following analysis:

24.4% volatile at 1000°C., incl. H₂ O and NH₃

5.2% nitrogen from NH₄ + radicals

1.4% sodium

10.3% aluminum

The latter calculates to 13.7% aluminum on ignited basis.

A Waring Blender was applied to distribute the aluminosilicate in 0.5 liter of water. The suspension was rinsed into a 1.5 liter beaker; the total volume was about 0.7 liter. The suspension was continuously stirred and heated while 0.2 liter of solution containing 58.2 g. Al(NO₃)₃. 9H₂ O and 14.5 g. of urea was added during 246 minutes, while the temperature was 172°-179°F. About ten minutes before adding the last of the solution of Al+++ and urea, pH 3.5 was noted. 50 ml. total (portions = 15, 15 and 20 ml.) of about 3 M. NH₄ OH were added to give pH 4. Stirring and digestion was continued for seven hours at an average of about 188°F. The solid was separated by filtration. The pH of the filtrate was close to 6. The solid was given three washings by the "Slurry-filter" method, using 0.3 liter of water in each instance. The resultant filter cake was dried in 230°F. oven. The aluminum addition of this Example calculated as about 3.0 × 10.sup.⁻⁶ moles Al+++/gram of aluminosilicate/minute.

After 230°F. drying the sigma value by X-ray diffraction was 76.7 cms. A 900°F. calcined portion had a sigma value of 54, surface area of 826 sq.m./g., and an aluminum content of 15.8% on an ignited basis, thus showing 2.1% by weight increase in aluminum on an ignited basis; a 1350°F. calcined portion had a sigma value of 38.0 cms. by X-ray diffraction and a surface area of 853 sq. m./g.

Thus the products of Examples II and II had almost identical sigma values after 1350°F. calcination, with each showing retention of the crystalline structure and protons from the decomposition of exchanged ammonium groups.

EXAMPLE IV

This example was prepared with portions of the same reactants in the same ratios as for Example II, but with a variation in procedure planned to precipitate a higher ratio of the aluminum outside of the crystalline aluminosilicate particles. All reactants were together prior to initiation of heating. The reactants were as follows:

5.8 g. Al(NO₃)₃.9H₂ O

20 g. Ammonium-exchanged aluminosilicate formed by the techniques of Example I

1.5 g. Urea; and water

The analysis of this aluminosilicate reactant is shown in Example III.

After dissolving the aluminum nitrate and urea in about 75 ml. water the solution was rinsed into a Waring Blender, and the total volume adjusted to about 0.25 liter. Into this solution was dispersed the crystalline aluminosilicate. The resultant suspension was rinsed into a tallform Berzelins beaker and total volume adjusted to 0.4 liter. While stirring continuously, heating was effected. During one hour the temperature rose to 159°F. During the next hour, the temperature rose to 192°F. The temperature was maintained at about 194°F.-195°F. for 3 hours, then increased to about 207°F. during the next hour and a pH 5 was measured. The solid phase was separated by filtration, then washed by "slurry-filter" procedure with three portions of water, whose volumes were 0.05, 0.05, and 0.06 liter, respectively. The final cake was spread in a flat dish and placed for drying in a 230°F. oven. The dried product had a sigma value of 7.8 cms. by X-ray diffraction. After 900°F. calcination in a programmed muffle, the product had a sigma value of 34.3 cms. another portion calcined for 2 hours at 1350°F. had a sigma value equal to 19.8 cms. Thus, the product structure is less stable using this preparation compared to the preferred method of the invention. The placement of all the reactants together before heating thus forms a less preferred catalyst.

EXAMPLE V

This example indicates another preparation to precipitate, using ammonium hydroxide rather than urea, nearly all of the added aluminum on the exterior of the crystalline aluminosilicate particles, a large percentage of which are about one micron across. The crystalline aluminosilicate and aluminum nitrate applied were portions of the same stocks used for Example IV. In a preliminary trial, the ratio was determined for neutralization of 2.0 g. Al(NO₃)₃.9H₂ O with about 3 molar NH₄ OH, to give pH 7. The reactants were as follows:

5.8 g. Al (NO₃)₃. 9H₂ O

20 g. Ammonium-exchanged aluminosilicate formed by the technique of Example I

20 ml. NH₄ OH solution about 3 molar and water

The analysis of the aluminosilicate reactant is shown in Example III.

A Waring Blender was applied to disperse the aluminosilicate in about 300 ml. of water, and the suspension then rinsed into an 800 ml. beaker. Next added, while stirring, was the NH₄ OH solution. Next, an aqueous solution of the aluminum nitrate, totaling about 50 ml., was added to the stirred, ammoniacal suspension, using about one minute for the addition. After moderate stirring, the pH was 7-8. The reaction system was then heated with stirring. After 20 minutes 175°F. was attained at which stage filtration was started. Water washing was by "slurry-filter" sequence. The first two washings were with 100 ml. water and a third and fourth with 125 ml. water each. After sampling the cake for observation by the electron microscope, the balance was dried at 230°F. and processed to pass 60 mesh.

Portions of the oven dried product were calcined in an electric muffle with programmed temperature for five hours at 900°F. One portion was removed and the other portion was heated to 1350°F. and held for two hours before removing. Subsequent X-ray diffraction study disclosed that this method of adding aluminum does not yield a product having good thermal stability. The sigma-values from X-ray diffraction were:

a. 75.8 cms. after oven drying

b. 21.9 cms. after 900°F.

c. 6.9 cms. after 1350°F.

A comparison of the sigma values of the products of Example IV and this example clearly indicates that the controlled hydrolysis of urea to form ammonia rather than the use of ammonia itself during the metal exchange process results in crystalline aluminosilicates of substantially improved thermal stability.

EXAMPLE VI

Three compositions having 1% Al, 4% Al and 6% Al added were prepared by a sequence of operations similar to those of Example III. During the preparation of the 4%-added-Al material, 15 ml. of 3 M HN₄ OH were added to moderately increase the pH. The addition was made 1/2 hour after the last of the solution containing urea and aluminum nitrate had been introduced; the pH change was from about 3.3 to 3.8.

In reference to Example III and the 4% Al preparation of Example VI, some NH₄ OH was used to adjust the pH moderately. This was done after a heating-aging period of substantial length and, therefore, does not make any significant change in the character of the alumina added. The corresponding rates of aluminum addition to the aluminosilicate slurry in this Example are about 2.3 × 10.sup.⁻⁶, 7.9 × 10.sup.⁻⁶ and 23 × 10.sup.⁻⁶ moles of aluminum per gram of aluminosilicate per minute, respectively.

EXAMPLE VII

Prior to activity testing, small-particle products such as those of Example II were processed to larger, calcined particles. The oven-dried products were mixed with four weight percent of Superflake Graphite No. 590, (distributed by Superior Flake Graphite Co., Chicago) then tabletted to 3/8 inch D × 1/16 inch L, cracked and sized to 10-14 mesh (Tyler) range. Small portions were placed into procelain crucibles and taken to 900°F. and held for 5 hours, using a temperature programmed electric muffle; i.e., 8 hours to 900°F., 5 hours at 900°F., and cooling to 400°F. and holding. The calcined portions were quickly transferred into vials.

Activity Test Method: Three grams, on ignited basis, of catalyst were charged into a 3/8 inch I.D.S.S. micro-reactor, fitted with a thermocouple onto the outer surface of the catalyst bed for measuring temperature. A moderate stream of pre-purified nitrogen was passed overnight at a temperature of 950°F. as a pre-conditioning period. The feedstock used was 99.9% isobutane and 0.1% n-butane, checked by gas chromatograph. The nitrogen flow was stopped, then isobutane feedstock started at a rate equal to 1.0 weight hourly space velocity, at one atmosphere pressure and 950°F. The products were routed so that samples could be directed into gas chromatographic equipment at intervals. Samples were analyzed to represent 5 mins., 30 mins., and 60 mins. "on stream". The chromatograph records were interpreted and calculated to give percent total conversion and percent isomerization. The aluminosilicate catalyst of Example II gave 66.21% total conversion and 31.28% isomerization.

EXAMPLE VIII

This example concerns a zirconium, hydrogen ion-exchanged aluminosilicate of this invention which has a high activity for cracking isobutane. A chromium exchanged aluminosilicate prepared by this method also had improved thermal stability and increased activity in hydrogenation reactions. The reactants were as follows:

33.3 g. ammonium-exchanged aluminosilicate prepared by the technique of Example I

3.4 g. urea

16.0 ml. zirconium acetate solution having 165 mg. ZrO₂ equivalent per ml. and water

The aluminosilicate had the following analysis:

29.2% volatile at 1000°C., incl. H₂ O and NH₃

4.2% nitrogen from NH₄ + radicals

1.10% sodium

9.74% aluminum

The latter calculates to 13.8% aluminum on an ignited basis.

A Waring Blender was applied to blend 250 ml. water, 33.3 g. aluminosilicate, then 1.7 g. urea, followed by 8.0 ml. of the zirconium solution. The resultant slurry was stirred and heated gradually, rising from 83°F. to 191°F. during 3.3 hours. The temperature was held at 185°F. or above for the next hour and then the solution was covered and maintained at about 75°F. ambient overnight. Later, the solid phase was resuspended by stirring and a solution of 1.7 g. urea in 10 ml. water, followed by 7 ml. rinse water were added. Some fifteen minutes later, 8.0 ml. of zirconium acetate solution was added, bringing total volume to about 220-225 ml. While continuing stirring, heating was started. During 2.8 hours, the temperature was increased to 197°F. The slurry was maintained within 184°F.-202°F. during the next 3.3 hours, with about 195°F. average. The slurry was then placed for filtration in an M-frit Pyrex unit. Three water washings were applied to the filtered product using the "Slurry-filter" sequence with 100 ml. of water used for each of the three washes. After taking a sample for electron microscopy, the majority of the cake was placed for drying at 230°F. overnight. The dried product was examined by X-ray diffraction; sigma value = 61.2 cms. The pattern did not disclose a separate zirconia phase. An analysis for nitrogen content from ammonium radicals and possible adsorbed urea disclosed 3.87% N. Then, 27 g. of the oven-dried product was well mixed with 1.2 gm. of flake graphite, processed by the procedure indicated in the forepart of Example VII, resulting in 22.9 g. of 10-14 mesh size particles and calcined with 900°F. maximum. The resulting analysis included 8.35% volatile at 1000°C. The values for Na, Zr, Al, and Si calculated to the following molar ratio, on ignited basis: 0.11 Na₂ O . 0.30 ZrO₂ . 1.0 Al₂ O₃ . 3.4 SiO₂. The surface area was 628 sq.m./g. using "Brunnauer-Emmett-Teller" procedure. By X-ray diffraction, the sigma value = 30.4 cms.

This catalyst displayed an unusually high activity for cracking isobutane when checked by the procedure disclosed in Example VII. The conversion was measured at 97.96%, and 122.4% cracking (due to secondary cracking). Thus, the procedure disclosed results indicating a zirconium-hydrogen ion-exchanged aluminosilicate of high cracking activity.

A portion of the zirconium, hydrogen ion-exchanged aluminosilicate was calcined to 1350°F. level, followed by X-ray determination of sigma value. The latter was equal to 15.0 cms. Thus, its thermal stability was better than a 1.0 to 4.0% added aluminum content aluminosilicate.

Table I summarizes the above Examples I to VI.

                                      TABLE I                                      __________________________________________________________________________     Example        I      II    III    IV    V     VI                                             NH.sub.4 -Na                                                                          Al-NH.sub.4                                                                          Al-NH.sub.4                                                                           Al-NH.sub.4                                                                          Al-NH.sub.4                                                                          Al-NH.sub.4                     __________________________________________________________________________     % Al Added     None   2     2      2     2     1    4     6                    Quantity of aluminosilicate                                                                   1016 g.                                                                               50 g. 199 g. 20 g. 20 g. 20 g.                                                                               20 g. 20 g.                               and less                                                        Aluminosilicate's % V.M.                                                        1000°C.                                                                               19.0   29.2  24.4   24.4  24.4  24.4 24.4  24.4                 Quantity of Al(NO.sub.3).sub.3.9 H.sub.2 O                                                    None   13.7 g.                                                                              58.2 g.                                                                               5.8 g.                                                                               5.8 g.                                                                                3 g.                                                                               11.6                                                                                 17.4 g.              Quantity of Urea       3.4 g.                                                                              14.5 g.                                                                               1.5 g.                                                                               None  0.75  3.0                                                                                  4.5 g.                                                              g.                             NH.sub.4 OH used                                                                              --     No    Yes, only                                                                             No    Yes   No   Yes   No                                               as pH,                                             Amount NH.sub.4 OH used                                                                       --     --    control                                                                               --    20 ml..sup.3M                                                                        --   15 ml..sup.3M                                                                        --                                               50 ml. 3M                                          Time to add Sol'n of                                                                          --     265   246 mins.                                                                             None.sup.(1)                                                                         None.sup.(2)                                                                         135  209                                                                                  104 min.             Al.sup.+.sup.+.sup.+ + urea                                                                           mins.                    min.                           Time for stirring and                                                           heating       10 × 1 Hr.                                                                      20 hrs.                                                                               7 hrs.                                                                               4 hrs.                                                                               0.35 hr.                                                                             7 hr.                                                                               12 hr.                                                                                6 hr.               Approximate Temp. °F.                                                                  180    191   ca. 187                                                                               ca. 195                                                                              to 175                                                                               150  180   201                  Washings       3      3     3      3     4     3    3     3                    Sigma Value, cms.                                                               Heating to 230°F.                                                                     76.4   --    76.7   71.8  75.8  76.7 70.4  73.0                  Calcination to 900°F.                                                                 --     43.7  54     34.3  21.9  48.0 41.8   4.0                  Calcination to 1350°F.                                                                --     36.7  38     19.8   6.9  12.7 12.7   0                   __________________________________________________________________________      Footnotes:                                                                     .sup.(1) Ex. IV reactants together before heating.                             .sup.(2) Ex. V, no urea used.                                            

EXAMPLE IX

This example illustrates the use of the presently useful metal, hydrogen ion-exchanged aluminosilicates. An aluminum, hydrogen ion-exchanged aluminosilicate prepared in a manner similar to the aluminosilicate of Example II is incorporated, using conventional techniques, into a silica-alumina matrix such that the aluminosilicate comprises about 20% by weight of the catalyst. This catalyst, in the conventional form of small particles for use in a fluidized bed reactor system, is contacted with a petroleum gas oil in a conventional fluidized bed reactor system at hydrocarbon cracking conditions. As a result, at least a portion of the gas oil is converted to hydrocarbon products having reduced boiling points. The catalyst is found to have outstanding thermal stability.

While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims. 

The embodiments of an invention in which the exclusive property or privilege is claimed are defined as follows:
 1. In a method for catalytically converting at least a portion of a hydrocarbon feed which comprises contacting said hydrocarbon feed at hydrocarbon conversion conditions with a catalyst comprising a metal, hydrogen ion-exchanged aluminosilicate wherein the metal is selected from the group consisting of aluminum, zirconium and chromium, the improvement which comprises preparing said metal, hydrogen, ion-exchanged aluminosilicate by a process comprising heating an aqueous slurry of a nitrogen compound forming ammonia on hydrolysis and a water-soluble salt of said metal with a predominantly ammonium-exchanged crystalline aluminosilicate having pores of diameter of about 6 to 15A. and a silica-to-alumina mole ratio of about 2:1 to about 20:1 to allow the metal to precipitate within the lattice structure of the aluminosilicate, and calcining the resulting material to form a metal, hydrogen ion-exchanged crystalline aluminosilicate, said process adding about 0.5 to 15 percent by weight of said metal based upon the total weight of the aluminosilicate on an ignited basis.
 2. A method according to claim 1 wherein the metal is aluminum.
 3. A method according to claim 1 further including the step of replacing with ammonium ions at least about 70% by weight of the initial sodium content of the aluminosilicate prior to the metal exchange.
 4. A method according to claim 1 wherein the metal is aluminum present from about 1.5 to 4 weight percent as said added metal.
 5. A method of claim 1 wherein the ammonia-forming compound is urea.
 6. A method according to claim 5 wherein from about 0.5 to 10 weight percent of said metal is added.
 7. A method according to claim 6 wherein during metal exchange the aqueous, heated slurry is maintained at above about 150°F.
 8. A method according to claim 7 wherein the aluminosilicate is a crystalline aluminosilicate having pores of a diameter of about 8 to 15A. and a silica-to-alumina mole ratio of about 3:5 to 6:1.
 9. A method according to claim 8 wherein the crystalline aluminosilicate has a silica-to-alumina mole ratio of about 4 to 5:1.
 10. A method according to claim 1 wherein the rate of adding the metal to the slurry is less than about 1 × 10.sup.⁻⁵ moles of metal per gram of aluminosilicate per minute.
 11. A method according to claim 8 wherein said metal is aluminum.
 12. A method according to claim 8 further including the step of replacing with ammonium ions at least about 90% by weight of the initial sodium content of the aluminosilicate prior to the metal exchange.
 13. A method according to claim 8 wherein the crystalline aluminosilicate has a silica-to-alumina mole ratio of about 4 to 5:1.
 14. The method of claim 8 wherein said hydrocarbon conversion comprises hydrocarbon cracking.
 15. The method of claim 8 wherein said hydrocarbon conversion comprises hydrocarbon reforming. 